Machine down, full of product – What can I do?

What should you do if your airless pump is full of paint but no longer working?

When working on a site, it can happen that an electric airless pump stops working while it is still full of paint. This can be a delicate situation, even urgent, because the paint remaining inside the machine could dry quickly and irreversibly damage the pump. Here’s a practical guide to react quickly and limit the damage.

1. Remain calm and assess the situation

First and foremost, don’t panic. Clearly identify the problem: is it a power cut, a blown fuse, a damaged cable, a blocked motor? Sometimes it’s just a simple electrical fault that can be quickly resolved.

• Check the power source (plug, extension lead, circuit breaker)

• • If you are using a large extension lead, remove it and connect the machine directly to the mains, without any extension lead.
• Check the pump switch
• Visually inspect the cables and connections
• If the machine starts up again, give priority to rinsing.

If the fault cannot be resolved quickly, go on to the next steps.

2. Prevent paint from drying

If the machine is full of paint (acrylic, dispersion, lacquer, etc.), it is essential to limit the downtime to avoid drying inside the circuit.

Quick actions to take :

• Dismantle the nozzle and lance and clean them immediately with water (or solvent if painting with glycerine).
• Relieve the pressure using the relief valve (tap) and close the valve again to prevent air from seeping in.
• Protect the ends of the hoses with plastic film or an airtight bag to slow the drying process
• Cover the inlet to the suction filter or bucket with a damp cloth or plastic film

If you don’t feel like continuing to look at the machine, or you can’t find the cause of the fault, you can contact an airless repairer to take the machine away as quickly as possible so that an approved professional can help you before the paint starts to solidify.

3. Try to empty the pump manually

If the pump is still full of paint but no longer lights up, try evacuating the material manually:

• Lower the pump assembly into the original paint bucket to empty it
• Disconnect the hoses and allow the paint to drain by gravity into a bucket (if possible)
• Use the relief valve to release the pressure and allow the paint to drain by gravity
• In some cases, it may be possible to extract the paint by suction or syringe

Warning: never attempt to dismantle the motor or internal parts on site without technical expertise.

4. Partial cleaning pending repair

If the pump cannot be restarted quickly, it is best to clean everything that can be cleaned immediately:

• Hose, lance, nozzle, gun filter and pump
• Pump exterior and handles

This will prevent the paint from drying in the removable parts and make it easier to repair later.

5. Contact the technical department

As soon as possible, contact the after-sales service or the machine’s distributor to explain the fault. The quicker you act, the more likely you are to avoid costly and time-consuming repairs.

Prepare the following information:

• Pump model and serial number
• Type of material used (paint, coating, etc.)
• Symptoms observed (more noise, disconnection, overheating, etc.)
• Operating conditions at the time of the breakdown

In conclusion

An airless pump motor that won’t start when the machine is full can be annoying, but with the right reflexes, you can save your equipment. Keep your cool, prevent the paint from hardening, clean what you can and call for technical support (Airless Discounter / Graco / Wagner). It’s better to react quickly than to have to replace an irreversibly damaged pump.

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